The present invention relates to a leadframe having a plurality of connections for electrical conductors, a plurality of contacts and at least two outer current bars, and to a connecting socket having a leadframe as well as to a system for transmission of electrical power, in particular from a plurality of solar modules (photovoltaic modules), having a connecting socket such as this. In order to devise a leadframe which occupies as little space as possible, at least one connection (32a-e) is provided for an electrical conductor between the outer current bars (34a, b). This allows the leadframe to have a compact physical shape. The invention is based on the discovery that leadframes are used in the prior art to bridge the distances between predetermined contact separations, offering the possibility of producing, in one stamped part, strip conductors which have different geometries. Furthermore, a connecting socket having such a leadframe is described, and a system for transmission of electrical power using such a connecting socket.
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17. A method for preparing a cable for connecting a plurality of current sources, wherein the cable comprises a plurality of leads for conducting different potentials in the cable, the method comprising:
stripping insulation from two ends of the cable at predefined points;
connecting the stripped ends to terminals of a lead frame, wherein the lead frame comprises a plurality of contacts, a plurality of current bars comprising connections between the terminals and contacts and a plurality of short residual sections of punched out lands on adjacent end faces of the terminals;
placing the cable ends and the lead frame in a connecting socket;
sealing the connecting socket; and
potting the connecting socket.
12. A system, comprising:
a connecting socket; and
a lead frame, comprising:
a plurality of terminals for electrical leads;
a plurality of contacts;
a plurality of current bars comprising connections between the terminals and the contacts, wherein at least two of the current bars are positioned as outer current bars, wherein each of the outer current bars comprises a first section, and wherein the first sections of the outer current bars are approximately parallel to one another; and
a plurality of short residual sections of punched-out lands on adjacent end faces of the terminals for electrical leads,
wherein at least one of the terminals is located between the outer current bars, and
wherein a longitudinal axis of the terminals is approximately transverse to a longitudinal axis of the first sections of the outer current bars.
1. A lead frame for an electrical connecting socket, the lead frame comprising:
a plurality of terminals for electrical leads;
a plurality of contacts; and
a plurality of current bars comprising connections between the terminals and the contacts, wherein at least two of the current bars are positioned as outer current bars, wherein each of the outer current bars comprises a first section, and wherein the first sections of the outer current bars are approximately parallel to one another,
wherein at least one of the terminals located between the outer current bars, and
wherein a longitudinal axis of the terminals is approximately transverse to a longitudinal axis of the first sections of the outer current bars,
the lead frame further comprising a plurality of short residual sections of punched-out lands on adjacent end faces of the terminals for electrical leads.
20. A system for transmitting electrical power, the system comprising:
a plurality of connecting sockets, wherein each of the connecting sockets has a lead frame, comprising:
a plurality of terminals for electrical leads;
a plurality of contacts;
a plurality of current bars comprising connections between the terminals and the contacts, wherein at least two of the current bars are positioned as outer current bars, wherein each of the outer current bars comprises a first section, and wherein the first sections of the outer current bars are approximately parallel to one another; and
a plurality of short residual sections of punched-out lands on adjacent end faces of the terminals for electrical leads,
wherein at least one of the terminals is located between the outer current bars, and
wherein a longitudinal axis of the terminals is approximately transverse to a longitudinal axis of the first sections of the outer current bars; and
at least one cable for connecting a plurality of current sources, wherein the at least one cable comprises a plurality of leads for conducting different potentials in the cable.
2. The lead frame according to
3. The lead frame according to
4. The lead frame according to
5. The lead frame according to
7. The lead frame according to
8. The lead frame according to
9. The lead frame according to
10. The lead frame according to
11. The lead frame according to
13. The system according to
14. A system according to
a cable for connecting a plurality of current sources, wherein the cable comprises a plurality of leads for conducting different potentials in the cable; and
a plurality of connecting sockets connected to the cable.
15. The system according to
16. The system according to
18. The method according to
19. The method according to
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The present invention relates to a lead frame having a plurality of terminals for electrical leads, a plurality of contacts and at least two outer current bars, to a connecting socket having a lead frame, and to a system comprising a connecting socket of this type for transmitting electrical power, particularly from a plurality of solar modules.
Within the context of the present invention, solar modules are particularly photovoltaic modules, in other words, modules which use incident light to generate electrical power, which can then be supplied to consumers.
From DE 102 32 281 A1, the use of a lead frame having current bars arranged parallel in sections within a connection assembly for connecting a connector cable to the stator winding ends of an external rotor motor is known. An arrangement of the contacts in accordance with the positions of the stator winding ends is also disclosed.
The problem addressed by the present invention is therefore that of specifying a lead frame having the smallest possible space requirement.
This is achieved with a lead frame of the type described in the introductory portion in that at least one terminal (32a-e) for an electrical lead is provided between the outer current bars (34a, b). In this manner, a compact configuration of the lead frame can be achieved. The invention is based upon the knowledge that lead frames are used in the prior art for bridging the gaps of predefined contact distances, thereby providing an option for producing conducting tracks of different geometries from a single stamped part.
To produce a particularly compact and simple lead frame, in a preferred embodiment of the invention the outer current bars have first sections that extend essentially parallel to one another. This can be implemented even more effectively when the longitudinal extension of at least one terminal for an electrical lead extends transversely to the longitudinal extension of the first section of the outer current bar.
To be able to produce a connection between the current bars and the terminals for electrical leads, bridges are provided between the first sections of the outer current bars and the terminals for electrical leads. Said bridges can be produced in a simple manner in the case of a stamped part.
In a preferred embodiment of the invention, a second section of each outer current bar is arranged at an angle in relation to the first section, and between at least one of the second sections and one of the terminals for an electrical lead, a bridge is provided. In this embodiment, the bridges are accessible even when leads are connected.
By arranging at least one current bar as an inner current bar between the two outer current bars, the configuration is kept compact even when additional current bars are used, and therefore keeps the space requirement low.
A further decrease in the space requirement can be achieved by aligning the contacts perpendicular to a plane that is spanned by the current bars and the terminals, as this results in a contacting of the contacts by a plug-type connector also perpendicular to the plane that is spanned by the current bars and terminals, and therefore perpendicular to the largest dimension of the lead frame.
The shape of the current bars is particularly preferably rectilinear, as this results in a simple structure of the lead frame and therefore also of the stamping tool.
In a particularly preferred embodiment, the lead frame has fewer contacts than terminals for electrical leads, so that even with a limited number of contacts, a higher-core cable can be uniformly installed and the individual leads of the cable can be reliably accommodated. This also makes a faulty connection, e.g., resulting from a confusion of the leads in wiring the lead frame, less probable than if the assignments of the individual leads to the terminals vary from lead frame to lead frame. The planned assignment of the leads to the contacts is achieved by the corresponding assignment of the bridges of the lead frame. Depending upon the wiring requirements, said assignments can vary according to a predefined pattern.
In a particularly preferred further development, adjoining end faces of the terminals for electrical leads are characterized by the presence of short residual sections of stamped-out lands. These are products of a particularly efficient production of the lead frame according to the invention, specifically by stamping, wherein the lands, which will no longer be required at a later time, are also punched out. In this case, however, the stamping tool will not punch the lands out with perfect precision at every location, and instead, small dimensional variations will have to be taken into consideration through tolerances. However, to avoid reducing the required material cross-section and as a result, reducing current carrying capacity, the tolerances are preferably taken into account in the opposite direction, so that residual sections of the punched-out lands cannot be avoided.
In order to maintain the necessary minimum distances while still achieving a production-friendly but nevertheless compact configuration, the distances among the terminals for electrical leads and the current bars, but also the distances between terminals for electrical leads and current bars measure ca. 1.8 mm to 4 mm and particularly preferably 1.8 mm to 3 mm.
The contacts are preferably spaced 4 mm to 12 mm and particularly preferably 9 mm to 10.5 mm from one another.
The lead frame, which produces the connection between cables connected thereto, is held within a connecting socket in order to protect it against contact, but also to protect it against undesirable factors.
In a preferred further development of the lead frame, the surfaces of the terminals that are provided for the leads to be connected jut out beyond the surfaces of the current bars.
This measure makes handling during connection of the terminals to the leads to be connected particularly simple, because the insulation exerts no force on the connection site, and because, even during connection, the connection site is kept free of foreign materials that could escape from the insulating material during connection.
To ensure a torsion-free connector assembly, in a preferred further development the plug connector face of the connecting socket is equipped with a mechanical code in the form of different geometries of the contact openings, so that a connector plug having a complementary connector face can be connected only in the predefined position.
To allow current to be supplied to a cable in a simple manner from a plurality of current sources, such as solar modules, for example, the cable mentioned in the introductory portion is characterized by a plurality of connecting sockets according to the invention, connected to the cable at predefined distances from one another.
The distribution of the load on the individual phases is particularly preferably implemented by means of bridges arranged in an alternating pattern in the connecting sockets.
In a particularly preferred further development of the invention, the cable is characterized by potted connecting sockets. In this manner, the connecting sockets are completely protected against penetrating particles and water (protection rating IP67).
A particularly simple and flexible production process is implemented by using a lead frame to produce a galvanic connection between terminals for electrical leads and contacts for a connector plug when connecting sockets are used for supplying electrical power to a cable.
A simple method for producing a cable comprises process steps, in which
In this process, the predefined respective assignment between terminals and current bars is implemented in that the connections between the terminals and the current bars are produced by first detaching predetermined bridges between the terminals and the current bars of the lead frame before the stripped leads are connected to the terminals.
Because the connections between the terminals and the current bars are produced by detaching predetermined bridges between the terminals and the current bars of the lead frame before the connecting socket is potted, the detachment step can be provided, adapted to the production process, at a time when it can be particularly advantageously integrated into the production process.
To make a connector plug having an interior space and a contacting area and having a housing formed from half shells safer, the interior space is filled with a casting compound which bonds with the cable and the housing. In this case, even in the event of damage to the connector plug, the fragments are held by the casting compound, so that access to leads that conduct potential is still prevented.
With a housing made of an impact resistant and UV resistant material, the connector plug becomes particularly tough, and therefore continues to provide effective protection for the components contained therein, even under intense UV irradiation.
To achieve good pottability, the connector contacts in the connector plug are sealed off from the interior space by a sealing plate, so that the casting compound cannot reach the connector contacts themselves and impair contact reliability.
Particularly preferably, the connector plug has sealing elements integrally formed on the half shells of the housing, which encompass the leads that extend out of the interior space to the connector contacts. This makes the use of a separate seal unnecessary, thereby simplifying the assembly of the connector plug.
Because the connector plug is embodied particularly for connecting a current source, particularly a solar module, to a collecting main with the interconnection of a connecting socket, the interaction of connector plug and connecting socket results in a particularly space-saving and reliable connection.
Particularly advantageous is a system for the transmission of electrical power, particularly from a plurality of solar modules, which comprises connecting sockets and connector plugs according to the invention and at least one cable according to the invention.
In what follows, the invention will be described in greater detail in reference to the figures. These show:
The housing 10 is formed from a bottom shell 12 and a top shell 14, which are latched to one another. The top shell 14 has a connection for a connector plug (not shown in this diagram) and the connector plug face, in other words, the region of the connecting socket 10 where the connector plug will be connected, has round openings 20 and at least partially angular openings 21. All the illustrated openings 20, 21 are intended for contacting and their number matches the number of contacts to be contacted. The figure shows only a housing with five openings. Naturally, if four contacts are used, a housing with four contacts will also be used.
The different shapes of the openings in the connector plug face serve as a mechanical code for the plug. Although round openings are universal, connector plugs that are incorrectly placed around the at least partially angular openings will not produce contact. Thereby, a correct fitting with the associated desired contact assignment is always ensured. Also shown in the figure is a sealing seat 15, which permits the accommodation of a seal known in the prior art, e.g., an O-ring, for sealing the transition between connecting socket 10 and connector plug 40 (not shown in this figure), so that the plug-type connector assembly as a unit satisfies the requirements of the relevant safety class. When the connecting socket 10 is not fitted with a connector plug, a sealing cap (not shown in the figure) can be placed on it and the openings thereby also sealed.
Inside the housing, cables 16, 18 are shown, which have been prepared for the electrical connection. Additionally, a so-called lead frame 30 is shown, which is provided for contacting and which will be described in greater detail below. The preparation of the cable 16, 18 comprises stripping the outer cable sheathing and removing the insulation around the individual leads so that they can be connected to one another. Preparation can also involve fanning out the leads, so that each of the leads is at a predefined distance from its adjacent lead and lies at a predefined position above the lead frame 30.
The cable openings 17 are embodied such that the housing of the connecting socket 10 can also function to provide cable relief. For this reason, the cable openings 17 are shaped such that the cable sheathing held in the interior of the housing of the connecting socket 10 is deformed such that its cross-section deviates from that of the cable openings 17 enough that it will not fit through them. Thereby, tensile stresses acting on the cables 16, 18 are carried into the housing of the connecting socket 10 and the cables 16, 18 are relieved.
The possible embodiments of the lead frame 30 are illustrated by way of example in
The lead frame 30 further comprises current bars 34a-d and contacts 36a-d. The current bars 34a-d also form the connections between the terminals 32a-e and the contacts 36a-d. The contacts 36a-d form the connection to the outside, in other words, the connection to a cable with the interconnection of a connector plug.
As is clear from the figure, five terminals 32a-e but only four contacts 36a-d are provided in each case. To be able to produce the desired configuration between terminals 32a-e and contacts 36a-d, bridges 38a-f are provided, which are disconnected based upon the respective configuration to be produced. This disconnection can be implemented, e.g., by punching out or simply detaching those bridges 38a-d that are not required. The terminals 32a-e and the contacts 36a-d are then assigned according to the remaining bridges, with the interconnection of the current bars 34a-d. As is also clear from the figures, in the illustrated embodiments the two terminals 32d, 32e that are closest to the contacts 36a-d are connected without a bridge to the current bars, and from there to the contacts 36b, 36c.
Between the terminals 32a-e, lands 39 are provided. However, these lands 39 are relevant only to the production and handling of the lead frame 30 because they produce the necessary rigidity, and they are removed during assembly of the lead frame 30, e.g., by punching out.
As is clear from
In
In this figure and the subsequent
With bridge 38a, lead L2 is connected to contact 36a, with the interconnection of current bar 34a. Or, if bridge 38a is punched out, it is not so connected. Lead L3 is connected via bridge 38d and via current bar 34b to contact 36d, or is not so connected. Lead L1 is connected either via bridge 38b and current bar 34a to contact 36a or via bridge 38c and current bar 34b to contact 36d, or not, as above. As a result, lead L2 is always connected to contact 36a, and lead L3 is always connected to contact 36d when the corresponding bridges 38a and 38d, respectively, are present, whereas lead L1, assuming the corresponding presence of bridges 38b and 38c, is connected either via current bar 34a to contact 36a or via current bar 34b to contact 36d. This will be described once again in detail in reference to the subsequent figure.
In
In
In
On the inside of the housing, sealing elements 44a, 44b are integrally formed, which together seal the interior of the housing off from the contacting area, so that the housing can be potted. The openings that are required for introducing the casting compound on one side and for venting on the other side are assumed to be known and are therefore not shown in this figure.
In each of the sealing elements 44a, 44b, openings 45 are provided, through which the leads or the contacts themselves can be fed. When the housing halves 41, 42 are joined, the sealing elements 44a, 44b form a seal, which seals the interior of the housing off from the contacts, so that a casting compound, with which the housing of the connector plug 40 will be filled, cannot reach the contact area. In this manner, an air-tight housing is produced; however, sealing compound will not impair contacting reliability.
As a result of this double-bending, which is also particularly clear from the side view shown in
In this case, the stripped leads 19 have already been attached to the lead frame 30 in a suitable configuration.
A suitable configuration of the lead frame 30 can again be produced by detaching individual bridges 38a-f. In this case, the bridges can also be removed after connection due to their positioning, i.e., as described above in reference to
As is clear to see, the respective lead sections 46 that still have insulation are separated from the actual connection sites on the terminals 32a-e.
The cable manager 47 has a plurality of channel-like recesses 48, the dimensions of which are such that the recesses 48 can accommodate insulated leads 46. These recesses 48 can also have additional projections, which can enable a clamping of the insulated leads 46.
However, it is particularly preferable for the double bend to correspond approximately to the thickness of the insulating layer of the lead 47, because this will minimize forces on the leads 47 and/or on the connection site to the terminals 32a-e.
Of course, lands and supports can also be provided in the housing. Latching means on the housing, e.g., latching catches and latching tabs, for securely joining the housing half shells are also known in the prior art and are not shown in this figure.
Starke, Cord, Schäfer, Sebastian, Huss, John, Scholz, Sebastian
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Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Apr 14 2011 | Phoenix Contact GmbH & Co. KG | (assignment on the face of the patent) | / | |||
Nov 15 2012 | STARKE, CORD | PHOENIX CONTACT GMBH & CO KG | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 029376 | /0641 | |
Nov 21 2012 | HUSS, JOHN | PHOENIX CONTACT GMBH & CO KG | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 029376 | /0641 | |
Nov 27 2012 | SCHAFER, SEBASTIAN | PHOENIX CONTACT GMBH & CO KG | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 029376 | /0641 | |
Nov 28 2012 | SCHOLZ, SEBASTIAN | PHOENIX CONTACT GMBH & CO KG | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 029376 | /0641 |
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